Production of metal carbide articles

ABSTRACT

A method for manufacture of Group IV metal carbide ceramic composites is provided wherein a permeable mass (14) of filler and a carbon source is contacted with a molten Group IVA metal (12). The molten metal (12) is maintained in contact with the permeable mass (14) for a sufficient period to infiltrate the permeable mass and to react the molten metal with carbon source to form a Group IVA metal carbide, composite. The filler may be a Group IVA metal carbide, or other inert filler, or a combination.

FIELD OF THE INVENTION

This invention relates to methods of making self-supporting ceramicbodies comprising carbides of the metals titanium, hafnium, orzirconium, and to the products of such methods.

BACKGROUND OF THE INVENTION

There is substantial interest in using ceramics and ceramic compositesin a variety of industrial, electrical, and structural applications.Numerous properties characteristic of these materials, such as hardness,refractoriness, thermal and electrical insulation, and resistance toerosion and corrosion, may be advantageously and beneficially utilizeddepending on the end-use. Also, ceramics and ceramic composites provideattractive alternatives to metals for manye xisting purposes, as well asenabling the development of new components for which metals or othermaterials are unsuitable.

There are several limitations, however, in substituting ceramics formetals, and the development and production of ceramic components fortechnologically advanced applications is attended with problems. Knownmethods of preparing ceramic components involves powder-basedfabrication, most typically at elevated tempertures and pressures, suchas by hot-pressing, reaction sintering and reaction hot-pressing. Thistechnology for fabricating ceramics manifests numerous deficiencies.These limitations or deficiencies include, for example, scalingversatility, capability to produce complex shapes, high costs ofsinterable powders, lack of batch-to-batch reproducibility of powderproperties, and substantial shrinkage on sintering. The presentinvention overcomes these limitations or deficiencies, and provides anovel method for reliably producing refractory metal carbide composites.

Ceramic carbides are well known in the art, and have been extensivelystudied in the ceramics industry. Also, components of these materials,made by conventional powder processing techniques, have achieved limitedcommercial success. A different process has been developed for themanufacture of siliconized silicon carbide, which produces a self-bondedceramic body. In one such process known as the REFEL process, moltensilicon is caused to infiltrate a porous preform of carbon and siliconcarbide. The molten silicon reacts with the carbon to form additionalsilicon carbide that partially fills the interstices of the preform. Theresulting ceramic components are relatively dense and brittle,consisting of silicon carbide and silicon. Although this process hasbecome well known and there is extensive patent coverage, there is nosuggestion that the REFEL process or other related processes areapplicable to other elements or metals. In fact, silicon is the onlyelement of Group IVA of the Periodic Table (C,Si,Ge,Sn,Pb) that forms aceramic carbide by reaction of the molten lement with carbon, andtherefore there is no reason to believe that other metals can be used ina similar process. (Any reference to the Periodic Table is from the "Handbook of Chemistry and Physics", 59th Edition, 1978-1979, CRC Press,Inc.,)

High temperature resistant articles are disclosed in U.S. Pat. No.3,288,573 to Abos. In accordance with the teach ings of this patent,there is disclosed a composite comprised of graphite particlessurrounded by an envelope of a carbide-forming material, includingtitanium, zirconium, hafnium, vanadium, nickel, tantalum, chromium,molybdenum, tungsten and silicon. According to the process of thispatent, a preheated porous graphite body is infiltrated by a molten massof silicon, or other identified metal, which partially reacts with thegraphite particles to form carbide envelopes around each particle.Because the resulting product conains free carbon, the product exhibitscertain qualities of graphite, most notably thermal shock resistance.

Among materials having potentially superior properties for particularcomponents are the carbides of the Group IVB metals, viz., titanium,zirconium, and hafnium. It is known to produce titanium, zirconium andhafnium carbides by a method known as self-propagating high temperaturesynthesis, in which a powder mixture of the metal and carbon is ignitedby local heating so that the resulting combustion front sweeps throughthe mixture resulting in the formation of the metal carbide. A majordisadvantage of this method, however, is that upon combustion ofadsorbed contaminants there is a virorous evolution of gases whichcauses a porous and inhomogeneous microstructure. Porosity also may becaused by melting of the reaction product in the intense heat of thereaction, followed by local shrinkage on solidification. In someinstances, an improvement in microstructure can be achieved byapplication of pressure during combustion.

SUMMARY OF THE INVENTION

The present invention broadly provides a new and improved method ofmaking ceramic articles comprising Group IVB metal carbide materials. Inthis broad sense, the method of the invention comprises the steps ofestablishing a body of parent metal selected from the group consistingof titanium, zirconium, and hafnium (Group IVB metal) in surface contactwith a permeable mass of filler material and a carbon source forreaction with the molten parent metal to form the carbide thereof. Thecarbon portion or moiety of the carbon source is present in astoichiometric amount relative to the Group IVB metal so thatsubstantially all carbon is reacted. The filler material comprises atleast one Group IVB metal carbide, or another relativelyinert filler, ora combination thereof.

The metal carbide filler in particulate form is admixed with the carbonsource to form the permeable mass or bed, which desirably is shaped as apreform. In addition, the bed or preform may include one or moresubstantially inert or nonreactive fillers as a reinforcing agent suchas metal oxides, carbides, nitrides, borides, and the like. The fillermaterial, whether as a Group IVB metal carbide and/or other fillermaterial, also serves as a diluent to control the exothermic nature ofthe carbon-metal reaction. Conveniently, the carbon source may beelemental carbon, present, for example, as graphite particles mixed withthe filler to constitute the porous bed or preform. Where desired, thecarbon source may be a reducible metal carbide such as molybdenumcarbide, and the resulting product comprises parent metal carbide andmolybdenum, and optionally unreacted parent metal, as well as a filler.

The parent metal is heated in a substantially inert atmosphere above itsmelting point to form a body of molten metal. The temperature andsurface contact ismaintained for a tiem sufficient to effect progressiveinfiltration of molten metal into the permeable mass and to permit orcause reaction of the metal with the carbon source to form a parentmetal carbide. The infiltration/reaction is continued for a timesufficient to at least substantially complete the carbide-formingreaction. Upon cooling, a self-supporting ceramic composite is producedcomprising a filler embedded by titanium carbide, zirconium carbide, orhafnium carbide formed in situ by the infiltration reaction between themolten metal and carbon of the carbon source. In a further embodiment,if an excess of parent metal is sued relative to the stoichiometricamount of carbon, the composite will include unreacted parent metal.

In one embodiment, the filler may be a carbide of a metal correspondingto the parent metal. That is, if the parent metal is titanium, the metalcarbide as filler may be titanium carbide. In that case, the end productcomprises titanium carbide formed as the reaction product and titaniumcarbide as filler. In a preferred embodiment of the present invention,the Group IVB metal carbide as filler (in additionto the carbon source)is of a Group IVB metal other than the parent metal. If the metalcarbide as filler is different from that of theparent metal, there isformed a solid solution of a ternary system between carbon and/or inertfiller and the two metals. In a further embodiment, the filler is arelatively inert compound such as a metal oxide, boride, nitride, etc.,rather than a carbide. A mixture of fillers, carbide and non-carbide,may also be employed. The choice of filler materials makes it possibleto tailor the properties of the resulting composite, as explained belowin greater detail.

The ceramic products produced by this invention comprise a composite ofGroup IVB metal carbide materials which includes (a) the reactionproduct of molten parent metal with the carbon source and (b) a metalcarbide filler and/or inert filler, a ternary carbide solid solution, orboth, and (c) optionally free parent metal, and/or reduced metal fromthe carbon source, depending upon such factors as the amount of parentmetal relative to the carbon source, type of filler(s) and type ofcarbon source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic, cross-sectional view in elevation showing anassembly of a body of parent metal partially embedded within a bed ofpermeable filler material and confined within a cylindrical graphitecrucible having a titanium carbide inner liner.

DETAILED DESCRIPTION OF THE INVENTION

In the practice of the present invention, a parent metal of Group IVBand a permeable mass comprising carbon and filler material(s) areoriented with respect to each other in surface contact so that moltenparent metal will infiltrate the mass. The parent metal, which isselected from the group consisting of titanium, hafnium and zirconium,may be the pure or relatively pure metal, commercially available mealhaving impurities or alloying constituents, or an alloy in which thedesignated parent metal is the major constituent. This positioning andorientation of the parent metal and permeable mass with respect to eachother may be accomplished in any one of several ways. For example, abody of parent metal may be embedded in the mass as illustrated in FIG.1, or the body of parent metal may be positioned adjacent to orcontiguous with a bed or other assembly of such filler materials.

The permeable mass or bed, which desirably may be shaped as a preform,comprises at least one filler and a carbon source for reaction with themolten parent metal to form the carbide thereof. The carbon source maybe elemental carbon or a metal carbide reducible by the molten parentmetla and the amount of parent metal as infiltrate is thatstoichiometrically required for the substantially complete reaction ofthe carbon moiety of the carbon source. Substantially all of the carbonmoiety of the carbon source is to be reacted because any unreactedcarbon would tend to reduce the hardness and possibly other importantproperties of the material. If elemental carbon is used as the carbonsource, the carbon ideally should be relatively pure, because manyimpurities typically associated with carbon, such as hydrogen or ahydrocarbon, evolve into gases at the processing temperatures, whichmight cause porosity in the ceramic product. Suitable elemental carbonincludes, for example, graphite, carbon black and petroleum coke, andthe carbon may be amorphous or crystalline. The carbon may be in anysuitable form such as powder, particle, fiber or flake, or the like, andmay range in size from minus 325 Tyler meshto minus 20 Tyler mesh, andmore preferably from about plus 100 Tyler mesh to minus 48 Tyler mesh.

Under the process conditions of this invention, the reaction tends to beexothermic, and certain grades, types or sizes of carbon can be tooreactive, thereby resulting in cracks or flaws in the ceramic product.For that reason, amorphous carbon or carbon powder that is too fine maybe too reactive and therefore not suitable as a carbon source unless theraction is moderated, as by the use of a suitable filler. The morecrystalline carbon tends to be less reactive, and graphite, especiallylarge flakes, is not as reactive as carbon black. It is generally moresuitable to use highly reactive grades of carbon in larger sizes inorder to moderate the reaction. Also, a filler incorporated into the bedor preform moderats the reaction, as well as serving as filler for thefinished product, which is explained below in greater detail.

Where desired, the carbon source may be one or more metal carbidesreducible by the molten parent metal. The metal carbide may be used incombination with elemental carbon, but the total carbon source presentis not more than the stoichiometric amount required for thesubstantially complete reaction of the carbon of the carbon source.Suitable metal carbides include, for example, molybdenum carbide,chromium carbide, cobalt carbide, iron carbide, nickel carbide, andvanadium carbide. It is recognized that a Group IVB metal carbide thatis different from the parent metal may be reducible by the parent metal,but the reaction is too slow to be very useful. When a reducible metalcarbide is used, the molten parent metal reacts to form a new carbideand reduced metal. For example, if iron carbide or molybdenum carbideare used as filler in conjunction with titanium parent metal, theresulting composite will contain titanium carbide and iron ormolybdenum. In this manner, a second metal constituent, e.g., iron ormolybdenum, is introduced into the finished product, which providesflexibility in tailoring the composite microstructure and properties. Insuch a case, molybdenum has a higher melting point and is more ductilethan titanium, and therefore it may be desirable to produce a titaniumcarbide ceramic containing molybdenum metal in themicrostructure inorder to obtain a product possessing one or more properties attributableto the presence of molybdenum. As a futher advantage, relative to directreaction with carbon by the parent metal, a reducible metal carbidemoderates the reaction process which tends to be exothermic, andtherefore a reducible metal carbide used alternatively or in combinationwith elemental carbon may be particularly advantageous in that therelatively high reactivity of the carbon is moderated by the metalcarbide.

In one embodiment of the invention, a metal carbide utilized as fillermay be of a metal corresponding to the parent metal or, more preferably,of a different metal. In either case, the metal carbide filler serves asa filler in the final product. For example, in a lay-up of titaniumparent metal and titanium carbide as filler for the bed or preform (alsocomprising the carbon source), the end product will contain bothcarbides, viz., the metal carbide initially present in the bed orpreform and the metal carbide formed by reaction between the parentmetal and carbon source. The metal carbide as filler helps to moderatethe reaction due to its non-reactivity and absorption of sensible heat,which may be particularly beneficial when employing a more highlyreactive carbon, e.g., amorphous carbon black. In addition, the GroupIVB metal carbides form an extensive range of ternary solid solutionsbetween themselves, e.g. (Zr_(x) Ti_(1-x))C, (Hf_(x) Ti_(1-x))C and(Zr_(x) Hf_(1-x))C. Therefore, in accordance with one embodiment of theinvention, when a Group IVB metal infiltrates a bed or preformcontaining a Group IVB metal carbide different from the parent metal,such solid solutions are readily formed. Still further, metal carbidesin addition to the Group IVB metal carbides may be used as a filler anddiluent in moderating the raction as long as the other metal carbidesare stable when in contact with the carbon source and the molten parentmetal. Such metal carbides include, for example, silicon carbide,tantalum carbide, and tungsten carbide. It thus will be observed thatthe choice of Group IVB metal carbides, either alone or in combinationwith other filler materials, also provides an advantageous method oftailoring the chemistry and microstructure, and hence the properties, ofthe product. In particular, thermal conductivity is substantiallysuppressed, electrical resistivity increased, and hardness enhanced byformation of the solid solutions. The relative proportion of the two ormroe components in the solid solution can be controlled by eitheralloying of the metal body, or by providing a mixture of powderedcarbides in the porous preform or bed. Where desired, both carbides canbe of the same metal, or more than one metal caride can be used asfiller, or a mixture of filler materials can be used, which can bepredetermined based on the properties required for the end product.

The filler material used in conjunction with the carbon source shouldhave a sufficiently high melting point to maintainstability under theprocess conditions. Typically, the melting point of the filler is chosenso as to be higher than the melting point of the parent metal and theprocess temperature. The process temperature can be lowered somewhat byutilizing an alloy of the parent metal, which possesses a lower meltingpoint than the pure parent metal, and thena filler with acorrespondingly lower melting point can be used in the process.

In accordance with the invention, a molten body of parent metal isdisposed in intimate contact with the permeable mass or bed along asurface or zone thereof, which comprises filler and a carbon source. Thebed may be oriented with respect to the parent meal in any manner aslong as the direction/development of the metal infiltration and reactionproduct will be towards and will engulf at least a portion of the bedwithout substantially disturbing or displacing it. Where desired, one ormore fillers which are substantially inert or nonreactive under theprocess conditions may be incorporated into the bed or preform. Suitableinert fillers may be chosen from the oxides, borides, nitrides andcarbides of the metals aluminum, titanium, zirconium, hafnium, tantalum,cerium, scandium, thorium, uranium, and yttrium. These inert fillers canbe useful in imparting desired end properties to the composite sructure.Any of the filler materials used in the bed may comprise ceramic ormetal fibers, whiskers, particulates, powders, rods, refractory cloth,reticulated ceramic foam, plates, platelets, solid spheres, and hollowspheres. Further, the bed or preform of filler materials may behomogeneous or heterogeneous.

A particularly effective method for practicing this invention involvesforming the bed of carbon source and filler material(s), into a preformwith a shape corresponding to the desired geometry of the finalcomposite part. The preform may be prepared by any conventional ceramicbody forming methods (such as uniaxial pressing, isostatic pressing,slip casting, sedimentation casting, tape casting, injection molding,filament winding for fibrous materials, etc.) depending on thecharacteristics of the carbon source and fillers. Initial binding of theparticles or fibers prior to reactive infiltration may be obtainedthrough light sintering or by use of various organic or inorganic bindermaterials which do not interfere with the process or contributeundesirable by-products to the finished material. The preform ismanufactured to have sufficient shape integrituy and green strength, andshould be permeable to the transport of molten metal. The preferredporosity of the preform depends on various factors including the ratioof the carbon reactant to inert filler, the volume growth of said carbonwhen reacting to form a parent metal carbide and the amount of porosity(if any) required in the reaction product. Such porosity may optionallybe filled by molten parent metal if present in excess of stoichiometricamount for carbide formation. Preferred preform porosity is betweenabout 5 and 90% by volume, and more preferably between about 35 and 60%by volume. The preform is then contacted with molten parent metal on oneor more of its surfaces for a time sufficient to complete the reactiveinfiltration of the parent metal to form a matrix extending through thepreform to its surface boundaries and preferably to substantially fillthe interstices of the preform with reaction rpoduct. The result is acomposite body of a shape closely or exactly representing that desiredin the final product, thus minimizing or eliminating expensive finalmachining or grinding operations.

The amount of carbon source(s) used in producing the product is lessthan or equal to that which is stoichiometrically required for itssubstantially complete reaction with the molten parent metal. Becausethe amount of parent metal relative to the required amount of carbonsource can be varied, it is possible to control or to modify theproperties of the completed composite body by varying the relativequantity of parent metal. When the parent metal and the carbon sourceare in stoichiometric amounts, the composite body properties tend to bedominated by the parent metal carbide, such that the body or matrixwould be less conductive or less ductile or less tough as compared to acomposite containing free metal. When an excess of parent metal is usedsuch that not all molten parent metal infiltrating the mass or bed isreacted, the matrix contains free metal or may be dominant in metal, andtherefore the composite body or matrix properties are influenced ordominated by the properties of the parent metal, most typicallyductility or toughness. Preferably, the quantity of parent metal inrelation to the interstitial pore volume and content of carbon source issuch that upon completion of the reaction, the pore volume is completelyfilled or nearly completely filled with reaction product carbide and/orunreacted metal. This is particularly desirable in producing asubstantially pore-free (dense) body.

In practicing one embodiment of this invention, the parent metalprecursor, e.g., titanium, is formed into an ingot, billet, rod, plate,or the like. The metal is at least partially embedded in a suitablecarbon source, e.g. elemental carbon, and a filler, such as for examplea Group IVB metal carbide. Optionally, the bed may include alternativefiller materials, e.g., alumina, zirconia, etc. This setup or assemblymay be surrounded by an ienrt material, typically in particulate form,which is non-wettable by and non-reactive with the molten metal underthe process conditions, and contained within a crucible or otherrefractory vessel. The top surface of the parent metal may be exposed,or the parent metal may be completely embedded or surrounded by the bedof carbon source and filler, and also the sourrounding inert bed may beomitted. This assembly is placed in a furnace and heated in an inertatmosphere such as argon, above the melting point of the parent metalbut preferably below the melting point of the desired parent metalcarbide so as to form a body or pool of molten metal. It should beunderstood that the operable temperature range or preferred temperaturemay not extend over this entire interval. The temperature range willdepend largely upon such factors as the composition of the parent metaland the choice of carbon source and filler materials. Molten metalcontacts the carbon source, and a parent metal carbide is formed as thereaction product. Upon continued exposure to the carbon source, theremaining molten metal is progressively drawn in the direction of aninto the mass containing the carbon source, to provide continudformaiton of reaction product. The composite produced by this methodcomprises the reaction product of the parent metal with the carbonsource and filler. If the parent metal is an alloy, the composite mayinclude one or more alloying constituents of the parent metal in eitherreacted or unreacted form. Also , the composite may contain liberatedmetal resulting from the use of reducible metl carbides, a solidsolution of Group IVB metal carbides, or an additional filler, asexplained above.

The articles produced by the method of this invention are relativelydense, self-supporting bodies exhibiting a metaland/or ceramicmicrostructure. The properties of the product can be varied widely,depending on the end use, as by choice of Gropu IVA metal carbidefillers, choice of other inert fillers, an ratio of metal to carbon. Forexample, a product of Ti/TiC made by infiltrating a bed of carbon andtitanium carbide with an excess of titanium, might be a useful wearpart.

FIG. 1 shows one embodiment of the apparatus in which the invention maybe practiced. The apparatus comprises a cylindrical graphite crucible 10provided with a titanium carbide inner liner 11. The cavity within theliner is partially filled with a permeable filler bed 14 comprised ofone or more relativley inert filler materials such as a Group IVB metalcarbide and a carbon source. A solid body of carbide-forming parentmetal 12 is embedded in the filler.

The graphite crucible and its contents are positioned within a furnace,such as, for example, within a graphite susceptor of an inductionfurnace (not shown). In such case, heat transfer from the susceptor tothe crucible outer wall is predominantly by rediation. The major mode ofheat transfer from the crucible wall to the contents thereof is byconduction.

An optical pyrometer (not shown) is positioned vertically above theapparatus and foxused on the interior of the crucible to enablemeasurement and control of furnace temperature.

The above-described apparatus was used for the following examples.

Examples 1, 2 and 3 demonstrate the conversion of titanium metal totitanium carbide by reaction with carbon within a titanium carbidefiller.

EXAMPLE 1

A rod of 99.7% purity titanium metal (from Alfa Product Division ofMorton Thiokol) 12.7 mm diameter by 29.5 mm high constituting 0.354 moleof Ti comprised the parent metal body of FIG. 1. The filler bedconsisted of 0.354 mole of carbon (in the form of minus 100 meshgraphite) and 0.023 mole of titanium carbide powder (also from theabove-named supplier).

The crucible and its contents were heated by the following procedure:

Ramp to 1500° C. in 30 minutes under 5 liters per

minute argon flow

Soak at 1500° C. for 10 minutes

Ramp to 1700° C. in 15 minutes

When the indicated temperature reached 1590° C., a temperature riseoccurred to a peak of 2200° C. followed by a drop-off to 1650° C.

Hold at 1700° C. for 5 minutes

Allow to cool

It was found after cooling that a cavity had formed in the areaoriginally occupied by the Ti rod.

The reaction product was removed from the crucible and the structureexamined under an optical microscope. It was evident that titanium metalhad penetrated into the filler and reacted completely therein to formnew titanium carbide. The latter constituent was present as a matrixembedding the titanium carbide filler particles and yielding a cohesivecomposite.

EXAMPLE 2

A rod of 99.7% purity titanium 12.7 mm diameter by 29.0 mm high (0.348mole) was embedded in a filler bed comprised of 0.24 mole of carbon inthe form of acetylene black and 0.24 mole of titanium carbide filler.

The crucible and its contents were heated by the following procedure:

Ramp to 1550° C. in 40 minutes under 3 liters per minute argon flow

Soak at 1550° C. for 10 minutes

Ramp to 1700° C.

Cut off power supply

The temperature continued to rise to a maximum of 1890° C.

Allow to cool

As in Example 1, a cavity was formed in the area originally occupied bythe metal. From microstructural examination of the reaction product itwas evident that titanium metal had penetrated into the filler andreacted completely therein to form new titanium carbide, yielding acohesive composite of titanium and titanium carbide.

EXAMPLE 3

A rod of 99.7% purity titanium metal 12.7 mm diameter by 30.0 mm high(0.363 mole) was embedded in a filler bed comprised of 0.25 mole ofminus 20 mesh particulate petroleum coke and 0.25 mole of titaniumcarbide powder.

Heating conditions were identical with those of Example 2. A similarcavity was observed after cooling the crucible and a similar product andproduct microstructure were obtained.

Example 4 demonstrates the conversion of zirconium metal to zirconiumcarbode by reaction with carbon within a titanium carbide filler and theformation of a titanium-zirconium carbide final product.

Two pieces of zirconium, nestled together and totalling 0.09 mole, wereplaced in the crucible of FIG. 1 and embedded in a bed comprising 0.09mole of carbon (graphite particles, minus 100 mesh) and 0.09 mole of TiCpowder. The crucible and its contents were heated to 2250° C. under afollowing atmosphere of argon, and held at that temperature for 3minutes. Temperature was then increased to 2300° C. and power shut off.

After cooling to room temperature, the composite reaction product wasremoved and examined under the optical microscope and by X-raydiffraction. A constituent comprising a solid solution having thecomposition (Zr₀.9 Ti₀.1)C was observed at the interface betweenresidual unreacted metal and the carbon/titanium carbide bed as apenetrated layer 2-3 mm thick. The residual metal contained precipitatedzirconium carbide.

What is claimed is:
 1. A method for producing a self-supporting ceramiccomposite comprising carbide, which method comprises:(a) stablishing ina substantially inert atmosphere a body of molten parent metalcomprising a metal selected from the group consisting of titanium,hafnium and zirconium in surface contact with a permeable masscomprising (i) a filler, and (ii) a carbon source for reaction with saidmolten metal toform a carbide of the molten metal, the carbon moiety ofsaid carbon source being present in no more thana stoichiometric amount;(b) maintaining said surface contact for a time sufficient to effectinfiltration of molten parent metal into said permeable mass and topermit reaction of saidmolten parent metal with said carbon source toform a parent metal carbide; and (c) continuing said infiltration andreaction for a time sufficient to at least substantially complete saidreaction and to thereby produce said self-supporting ceramic composite.2. The method of claim 1, wherein said filler comprises a carbide oftitanium, hafnium, or zirconium.
 3. The method of claim 1, wherein saidfiller comprises a filler material which is substantially inert to themolten parent metal or a forming metal carbide under the processconditions.
 4. The method of claim 1, claim 2 or claim 3, wherein saidcarbon source is elemental carbon ranging in size from about minus 325Tyler mesh to about minus 20 Tyler mesh.
 5. The method of claim 4,wherein said carbon source comprises petroleum coke.
 6. The method ofclaim 1, claim 2 or claim 3, wherein said carbon source comprises ametal carbide reducible by said molten parent metal.
 7. The method ofclaim 6, wherein said reducible metal carbide comprises a materialselected from the group consisting of molybdenum carbide, chromiumcarbide, cobalt carbide, iron carbide, nickel carbide, and vanadiumcarbide.
 8. The method of claim 1, claim 2, of claim 3, wherein saidfiller comprises a material selected from the group consisting offibers, particulates, reticulated foam, plates, solid spheres, andhollow spheres.
 9. The method of claim 1, claim 2, or claim 3, whereinsaid permeable mass comprises a preform, and said infiltration and saidreaction occur throughout at least a portion of the volume of saidpreform, whereby said self-supporting body obtained in step (c) has theconfiguration of a portion of said preform.
 10. The method of claim 1,claim 2, or claim 3, wherein said mass comprises less than thestoichiometric amount of said carbon source to react with said moltenparent metal wherein not all molten parent metal infiltrating said massis reacted, thereby producing a self-supporting body also containingunreacted parent metal.
 11. The method of claim 2, wherein said carbidecomprises a metal different from said parent metal thereby forming aternary solid solution of said parent metal, said different metal andcarbon.
 12. The method of claim 1, claim 2, or claim 3, wherein saidfiller comprises a material selected from the group consisting ofwhiskers, powders, rods, wire cloth, refractory cloth, and platelets.